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I've always wondered why they redid the flutter pony moulds - maybe the originals were damaged or lost? It's clearly not just a casting thing, they're separate designs. The walking flutter pose has the same small/big head variations.
It's a real mystery, especially considering the second set of flutters (Cloud Puff, Tropical Breeze, etc) ALSO have big-head / small-head variations!
But why would they remake two entire mould sets (not a fast, easy or cheap process) just for another factory? It would make more sense to cast up additional bronzes from the original masters - unless those masters were lost/destroyed, or the creation method bars such duplication (lost wax for example). It's a very long, expensive process creating a new master / pose, which is why Hasbro reused poses for the majority of sets and still does to this day. Even retooling master moulds was generally favoured over a complete replacement. The only other 'remakes' I can think of are the Princess Ponies and Sundae Best, both of which needed modifications for their special features. The fact that both 'big' and 'small' face variants seem to occur with equal regularity also doesn't fit with the hypothesis of additional factories being supplied with masters unless there was a /huge/ influx of new factories, and again if so, why only Flutters but none of the other sets?